Wallboard system and methods of installation and repair

ABSTRACT

A wallboard system composed of panels having weldable joint areas is disclosed. The panels are joined together by a connector that can also be utilized to align adjacent panels. Each panel has a reinforcement grid either embedded therein or attached thereto. Preferably, the reinforcement grid is made of a network of horizontal and perpendicular conduits that extend across the panel. The connector is interposed between the sidewalls of adjacent panels and the end portions of the conduits from each panel are configured to mate with respective areas of the connector, thereby forming a flush joint between adjacent panels. The connectors may include a generally L-shaped corner bead that fills the joint areas between panels forming inside or outside corners.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to wallboard systems, and inparticular, relates to a reinforced drywall system having weldablejoints.

2. Description of the Related Art

Wallboards, such as drywall, plasterboard, cement fiberboard, mineralfiber panel, and sheet rock, generally refer to large rigid panels usedin construction especially for sheathing the interior and exteriorwalls, ceilings, and floors of residential or commercial buildingstructures. A conventional wallboard is typically made of a gypsum coresandwiched between two sheets of facing paper. The wallboards aremounted to a support frame such as a wooden stud or the like usingnails, screws, or other similar fasteners. The edges of a wallboardpanel are typically beveled or tapered so as to be generally thinnerthan the body of the panel. During installation, multiple sheets ofwallboards are usually adjoined together in an abutting manner with thetapered edges of each sheet secured to a stud. Joint tape and compoundare commonly applied to the recessed regions formed between the abuttingtapered edges of adjoining sheets to provide a flat exterior wallsurface.

While conventional wallboard systems are inexpensive and easy tomanufacture, they have a number of drawbacks. For example, the paperfacing material of the drywall is a source of nourishment for fungus,and thus promotes mold growth particularly in moist environments.Another problem often encountered in conventional drywall systems isnail pops. Nail pops generally refer to the condition whereby thefastener head has sunk or skewed past the paper facing into the gypsuminner lining which in turn causes the cosmetic joint compound to poploose or causes the actual fastener to become visible, thereby formingan unsightly protrusion in an otherwise smooth wall surface. Nail popsin drywall are often caused by shrinkage or movement of the wooden studrelative to the wallboard after installation. While there are a varietyof other reasons why nail pops occur, all of which can be traced to oneor more fastener heads failing to remain stationary against a thin pieceof drywall cover paper. Another drawback associated with conventionalwallboard systems is that during installation, each side edge of thewallboard panel must be nailed or secured to a stud to prevent the edgesfrom jutting outwardly and also to ensure that the edges of adjoiningpanels are flush with one another. As such, each panel must be preciselypositioned and sized so that the joint between two adjacent panels arealigned against a stud, which can be an inefficient and time consumingprocess.

It is thus an object of the present invention to provide a wallboardsystem and methods of installation and repair which will overcome orameliorate one or more of the disadvantages of the prior art.

SUMMARY OF THE INVENTION

As used herein, the term “wallboard” is a broad term and shall have itsordinary meaning and shall include, but not be limited to, gypsum board,plasterboard, cement fiberboard, mineral fiber panel, and Sheetrock usedfor forming interior walls, ceilings, or floors.

The term “drywall” is a broad term and shall have its ordinary meaningand shall include, but not be limited to, building materials such assheets or panels comprised primarily of gypsum and used primarily forsheathing interior walls and ceilings.

The term “inside corner” is a broad term and shall have its ordinarymeaning and shall include, but not be limited to, a corner formed by theexterior faces of two abutting wallboards wherein the exterior faces arepositioned at an angle of less than 180 degrees relative to each other.

The term “outside corner” is a broad term and shall have its ordinarymeaning and shall include, but not be limited to, a corner formed by theexterior faces of two abutting wallboards wherein the exterior faces arepositioned at an angle of greater than 180 degrees relative to eachother.

The term “exterior face” is a broad term and shall have its ordinarymeaning and shall include, but not be limited to, the side of awallboard that does not face the wall stud or ceiling joist to which thewallboard is fastened.

The term “corner bead” or “bead” is a broad term and shall have itsordinary meaning and shall include, but not be limited to, elongatedcorner reinforcements configured to finish the joint area of inside andoutside corners.

In one aspect, the preferred embodiments of the present inventionprovide a wallboard system. The system generally includes a plurality ofdrywall panels, each of the panels having a plurality of conduitsextending through the drywall panel between a first edge and a secondedge. Each panel is preferably 4 feet by 8 feet and less than 1 inchthick, however, other size panels are available and equally adaptable,and depending on application may even be more advantageous. The systemfurther includes a connector comprising a plurality of protrusions sizedto fit within the respective conduits. Preferably, the connectorcomprises an elongated strip from which the protrusions project. In apreferred embodiment, the protrusions project from opposing surfaces ofthe strip. In another preferred embodiment, the connector has at leasttwo surfaces that are disposed at an angle relative to each other andthe protrusions project from the two surfaces. The conduits can beparallel and extend between opposite edges of each panel. In certainembodiments, the system further includes a second plurality of conduitswhich are orthogonal to the first plurality of conduits. In someimplementations, the spacing between the conduits is the same for thefirst and second plurality of conduits. The conduits are preferably madeof a material selected from the group consisting of polyvinyl chloride(PVC), polycarbonate, polystyrene, ABS, nylon, PET, acrylics orcombinations thereof. In a preferred embodiment, the protrusions on theconnector and the conduits are welded together, preferably solventwelded together.

In another aspect, the preferred embodiments of the present inventionprovide a drywall panel having a plurality of elongated reinforcementsextending through from one edge to another. In one embodiment, thedrywall panel further comprises indicia on the exterior of the panelindicating position of the reinforcements. In another embodiment, thedrywall panel further comprises a gypsum core, wherein the elongatedreinforcements are embedded in the gypsum core. The elongatedreinforcements preferably comprise a network of horizontal andperpendicular reinforcements such as but not limited to conduits.Preferably, an end portion of each reinforcement protrudes outwardlyfrom an edge of the panel. In one embodiment, the drywall panel furthercomprises a gusset disposed along the edge of the panel. Preferably, thegusset has a plurality of openings configured to receive the endportions of the reinforcements.

In yet another aspect, the preferred embodiments of the presentinvention provide a plurality of panels comprised of gypsum, each of thepanels having two opposing faces and an edge portion comprised of amaterial other than gypsum. The material has a bonding property whichallows an edge portion of one panel to be attached to an edge portion ofanother panel by bonding so as to securely fasten the edge portionstogether. In one embodiment, the bonding property comprises a propertywhich allows the material to be weldable to other materials. In anotherembodiment, the edge portion material is plastic. In yet anotherembodiment, the edge portion comprises a planar surface that isperpendicular to the opposing faces of the panel. In yet anotherembodiment, the edge portion of one panel is attached to the edgeportion of another panel by bonding the edge portions to a connectorthat is disposed therebetween.

In yet another aspect, the preferred embodiments of the presentinvention provide a wallboard panel comprised of gypsum and the panelhas an edge portion comprised of a plastic material. In one embodiment,the edge portion comprises the perimeter of the wallboard panel. Inanother embodiment, the edge portion comprises opposing edges of thepanel. Preferably, the opposing edges being interconnected byreinforcements extending through the gypsum. In yet another embodiment,the edge portion comprises a frame that borders the edges of each panel.In some implementations, the plastic material is attached to a face ofthe wallboard panel.

In yet another aspect, the preferred embodiments of the presentinvention provide a corner bead for finishing a corner of abutted,non-overlapping drywall panels. The corner bead is configured to fitwholly between ends of the abutted panels without overlapping onto facesof the panels. In one embodiment, the corner bead comprises twoelongated surfaces disposed at an angle relative to each other, whereineach surface is configured to contact an end of a respective abuttingpanel. In one implementation, the angle is preferably about 30, 45, 90,or 135 degrees. In another implementation, the angle is preferablyadjustable. Preferably, the corner bead further comprises a plurality ofprotrusions extending from each of the elongated surfaces. In certainpreferred embodiments, the corner bead is configured to attach to thepanels without taping or nailing. The corner bead can be configured forfinishing an inside corner or an outside corner.

In yet another aspect, the preferred embodiments of the presentinvention provide a wallboard system. The wallboard system generallyincludes a pair of panels comprised of gypsum core wherein each of thepanels has an edge portion comprised of material other than gypsum. Thewallboard system further includes a corner bead between edges ofadjacent panel. Preferably, the corner bead has a pair of surfacesdisposed at an angle relative to each other. Preferably, the corner beadis comprised of a material, wherein the edge portion material and thecorner bead material have bonding properties which allow respective edgeportions of the panels to be attached to respective surfaces of thecorner bead by bonding.

In yet another aspect, the preferred embodiments of the presentinvention provide a method of installing a plurality of wallboardpanels. The method includes positioning a first drywall panel having anedge portion comprised of a material other than drywall adjacent to asecond drywall panel having an edge portion comprised of a materialother than drywall, and attaching the edge portion of the first drywallpanel to the edge portion of the second drywall panel by a methodselected from the group consisting of cement bonding, adhesive bonding,solvent welding, heat welding, ultrasonic welding, and combinationsthereof. In one embodiment, the step of attaching the edge portions ofthe drywall panels comprises placing a connector adjacent a respectiveedge portion of each drywall panel and adhering the connector to therespective edge portions. In a preferred implementation, placing aconnector adjacent to a respective edge portion comprises placing aconnector having spaced protrusions extending therefrom adjacent an edgeof the first drywall panel, inserting a plurality of the protrusionsinto the edge portion of the first panel, inserting another plurality ofthe protrusions into the edge portion of the second drywall panel, andadhering the inserted plurality of protrusions to the edge portionmaterial. In one embodiment, adhering the inserted plurality ofprotrusions to the edge portion material comprises solvent bonding theprotrusions to the edge portion material. In another embodiment, themethod further includes inserting a fastener into a face of the drywallpanel, through a conduit embedded in said panel, and into a supportframe.

In yet another aspect, the preferred embodiments of the presentinvention provide a method of repairing a drywall panel. The methodcomprises cutting an opening in a drywall panel having a plurality ofconduits extending therethrough, preparing a drywall insert sized to fitwithin the opening such that a plurality of conduits through the insertis parallel to the plurality of conduits in the panel, and inserting atleast one connector into at least some of the conduits so as to fastenthe insert into the panel. In one embodiment, the method furthercomprises orienting the inserts so that a second plurality of conduitsof the insert orthogonal to the first plurality of the insert isparallel to a second plurality of conduits of the panel orthogonal tothe plurality of conduits to the panel.

In yet another aspect, the preferred embodiments of the presentinvention provide a frame for mounting gypsum drywall. The framecomprises a perimeter edge portion configured to retain a panel of thegypsum drywall with plural edges of the panel adjacent respective pluraledges of the perimeter edge portion. The frame further comprises abacking portion that is attached to the edge portion and disposed withina space defined by the perimeter of the edge portion. In one embodiment,the edge portion comprises a plurality of elongated sections defining asubstantially rectangular area. Preferably, at least one elongatedsection is made of a plastic material. In another embodiment, at leasttwo of the elongated sections are disposed orthogonally to each otherthereby forming a corner. In one implementation, the edge portion isapproximately 4 feet wide and 8 feet long. The backing portionpreferably extends across the space defined by the perimeter of the edgeportion. In one embodiment, the backing portion comprises a plurality ofconduits.

In yet another aspect, the preferred embodiments of the presentinvention provide a method of applying a frame to a gypsum drywallpanel. The method comprises the steps of providing a substantially rigidframe having a backing material disposed within a space defined by theframe and attaching the gypsum drywall panel to the frame. In oneembodiment, the step of providing the frame comprises joining aplurality of elongated legs together in a manner such that at least twoof the legs are disposed orthogonally to each other. In anotherembodiment, the step of attaching the gypsum drywall panel to the framecomprises attaching a face of the gypsum drywall panel to the elongatedlegs. In yet another embodiment, the step of forming the frame comprisesattaching a backing material to at least one edge of the frame. In apreferred embodiment, the backing material is in the form of a conduit.Preferably, attaching the gypsum drywall panel comprises attaching aface of the panel to the backing material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B are schematic illustrations of a wallboard system of certainpreferred embodiments of the present invention;

FIG. 2 is a schematic illustration of the wallboard system of FIGS.1A-1B showing two adjacent wallboard panels connected together by awelded joint;

FIGS. 3A-3B are schematic illustrations of one embodiment of aconnecting member of the wallboard system of FIG. 1A;

FIGS. 4A-4C are schematic illustrations of certain alternativeembodiments of the connecting member of the wallboard system of FIG. 1A;

FIGS. 5A-5C are schematic illustration of a wallboard panel of certainpreferred embodiments of the present invention;

FIG. 6 is a schematic illustration of one embodiment of the wallboardpanel configured to reduce nail pops;

FIG. 7 illustrates a manner in which the wallboard system of FIG. 1A canbe installed;

FIGS. 8A-8B illustrate a manner in which the wallboard system of FIG. 1Acan be repaired;

FIGS. 9A-9B illustrate a corner bead of one preferred embodiment of thepresent invention;

FIG. 10 illustrates the corner bead of FIGS. 9A-9B being used to finishan outside corner of one preferred embodiment;

FIGS. 11A-11E are schematic illustrations of a corner bead of anotherpreferred embodiment of the present invention; and

FIG. 12 illustrates the corner bead of FIGS. 11A-11E being used tofinish an inside corner of one preferred embodiment;

FIGS. 13A-13B are schematic illustrations of a wallboard frame of onepreferred embodiment of the present invention configured to retrofitpre-formed drywall panels.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1A is a schematic illustration of a wallboard system 100 of onepreferred embodiment of the present invention. The wallboard system 100generally includes a first wallboard panel 102 a, a second wallboardpanel 102 b, and a connecting member 104 for aligning and joining thepanels 102 a, 102 b together in a manner to be described in greaterdetail below. As shown in FIG. 1A, each wallboard panel 102 a, 102 b isgenerally rectangular in shape, having two opposing faces 106 a, 106 band sidewalls 108 a-d extending therebetween. In a preferred embodiment,each wallboard panel is 4 feet by 8 feet and has a thickness of nogreater than about 1 inch, preferably no greater than about ¾ inch, morepreferably no greater than about ⅜ inch, although it will be appreciatedthat a variety of different panel shapes and dimensions are contemplatedto be within the scope of this invention.

As also shown in FIG. 1A, each wallboard panel 102 a, 102 b comprises acore material 110 and reinforcements 112 extending therethrough. Thecore material 110 can include but is not limited to gypsum, concrete,fiberglass, and combinations thereof. The reinforcements 112 preferablycomprise a substantially rigid material that is selected to providestrength and reinforcement to the panels 102 a, 102 b. Preferably, thereinforcements 112 are made of a material that can be adhered to theconnecting member 104 using a variety of known techniques such assolvent welding, heat welding, ultrasonic welding, cement bonding andthe like. In a preferred embodiment, the reinforcements 112 are made ofa solvent weldable or solvent bondable material such as polyvinylchloride (PVC), polycarbonate, polystyrene, ABS, nylon, PET, acrylics,or combinations thereof. Solvent welding or solvent bonding is a knowntechnique used for joining parts formed of certain plastic materials.Generally, the solvent dissolves the surface of the two mating parts andallows the materials to flow together. After the solvent evaporates,what is left is a material-to-material bond. A more detailed descriptionregarding solvent bonding or solvent welding is provided in U.S. Pat.No. 5,821,293, which is hereby incorporated by reference in itsentirety.

In the embodiment shown in FIG. 1A, the reinforcements 112 are in theform of a plurality of conduits such as plastic tubing. The diameter ofeach tubing is preferably approximately 1 inch wide. The conduits form areinforcement grid that is preferably embedded in the core material 110.The reinforcement grid is comprised of a first group of parallelconduits 114 a extending between a pair of opposing edges 115 a, 115 bof the panel 102 a, 102 b and a second group of parallel conduits 114 bextending between a second pair of opposing edges 117 a, 117 b of thepanel. Preferably, the first and second groups of conduits 114 a, 114 bare orthogonal to each other so as to form a network of uniformly spacedhorizontal and perpendicular conduits. In one implementation, thespacing between adjacent conduits in the first group of conduits 114 ais the same as the spacing between conduits in the second group 114 a.In a preferred implementation, the spacing between adjacent conduitsextending in the same direction is about 4 inches. As will be describedin greater detail below, the reinforcements 112 are configured toprovide numerous advantages to the wallboard system shown in FIG. 1A,including but not limited to, reinforcing the strength of the individualdrywall panels, facilitating the alignment of the panels duringinstallation, and forming weldable joints between adjacent panels.

As shown in FIG. 1A, the end portions of each reinforcement 112 arepreferably substantially flush with at least one sidewall 108 a-d of thepanel so as to form a plurality of openings 116 in the sidewalls 108a-d. The connecting member 104 of the wallboard system 100 comprises anelongated strip 118 having two opposing surfaces 120 a, 120 b and aplurality of protrusions 122 extending from each surface 120 a, 120 b.The protrusions are preferably configured to be received by a respectiveopening 116 formed in the sidewalls 108 a-d of the wallboard panel 102a, 102 b. Preferably, once inserted, the protrusions 122 establishcontact with the conduit by way of an interference fit. In someimplementations, the connecting member 104 also serves as an alignmentguide in aligning adjacent panels together by inserting the protrusionsinto the appropriate openings on the sidewalls of the panels. As such,the wallboard systems advantageously utilize the connecting member 104to quickly and conveniently guide the alignment of two adjacentwallboard panels through an interference fit of the protrusions on theconnecting member and the openings formed on the panel sidewalls. Incertain preferred embodiments, the connecting member is also made of abondable material such as PVC and can be solvent bonded, cemented, oradhered to the conduits.

During installation, the connecting member 104 is preferably sandwichedbetween the sidewalls 108 a, 108 b of adjacent wallboard panels suchthat protrusions 122 on one surface 120 a of the connecting member 104are inserted into openings 116 in the sidewall 108 b of the firstwallboard panel 102 a while protrusions 122 on the other surface 120 bof the connecting member 104 are inserted into openings formed in thesidewall 108 a of the second panel 102 b. Preferably, each insertedprotrusion contacts the respective conduits therein. In one embodiment,a solvent or solvent primer is applied to the protrusion prior toinsertion into the sidewall openings so as to allow the connectingmember 104 to be solvent welded or bonded to the conduits. In anotherembodiment, a volume of the solvent can be encapsulated in the conduitsand can be released upon pressure exerted by the protrusion. In yetanother embodiment, the conduits and the connecting member can be weldedtogether using heat welding, ultrasonic welding or other known methods.Advantageously, the conduits in the wallboard panels in conjunction withthe connecting member allow adjacent abutting panels to be fixedlybonded to each other and form a joint that is flush with the exteriorface of the panels.

FIG. 1B illustrates an alternative embodiment of the wallboard system100 in which the reinforcements 112 extend outwardly from at least onesidewall 108 a-d of the panel 102 a, 102 b and the end portions 124 ofthe reinforcements 112 protrude from the sidewalls. In this embodiment,the connecting member 104 comprises an elongated base 118 having aplurality of openings or indentations 126 formed therein. The openings126 are configured to receive the end portions 124 of the reinforcements112 that protrude from the sidewalls 108 a-d of the wallboard panels 102a, 102 b. The end portions 124 of the reinforcements 112 can be bondedto the connecting member 104 via solvent welding, heat welding,ultrasonic welding, cementing, adhesives or other known methods. Whilethe preferred embodiments illustrated herein show the reinforcements ascomprised of conduits, it will be appreciated that the reinforcementscan assume a variety of other configurations, such as non-tubular formand/or non-hollow without departing from the spirit of the invention.

FIG. 2 is a schematic illustration of the wallboard system 100 of FIG. 1showing the first and second wallboard panels 102 a, 102 b beingsecurely fastened to each together by bonding, such as by welding, atleast some of the conduits of each panel to the same connecting member.As shown in FIG. 2, the two wallboard panels 102 a, 102 b form a jointarea 200 that is flush with the exterior faces 202 of the panels 102 a,102 b. The flush joint area 200 substantially eliminates the need forjoint compound to fill the joint regions which are recessed in mostconventional drywall systems. Additionally, since the panel sidewallsare fixedly bonded to each other, the joint area between the panels canbe positioned between studs as there is no longer a need to nail theindividual panel edges to studs. Hence, there is also no longer a needto bevel the edges of drywall panels to facilitate nailing to the studs.

FIGS. 3A and 3B are partial schematic illustrations of the connectingmember 104 of one preferred embodiment. FIG. 3A is a partial side viewof the connecting member 104 showing the protrusions 122 extending fromthe first surface 120 a of the connecting member 104. In one embodiment,the protrusions are semicircular and have a diameter of about ⅞ inch.However, it will be appreciated that the protrusions and the connectingmember can take on the form of a variety of other shapes and dimensions.FIG. 3B is a partial cross-sectional view thereof, showing protrusions122 extending from generally the same location on opposing surfaces 120a, 120 b of the connecting member 104. The protrusions 122, preferablysemicircular in shape, are configured to be received in respectiveopenings formed in the sidewalls of adjoining panels.

FIGS. 4A, 4B and 4C are partial schematic illustrations of theconnecting member 104 of other preferred embodiments. FIG. 4A is apartial side view of the connecting member 104 showing the protrusions122 extending from the first and second surfaces 120 a, 120 b are offsetfrom each other. FIG. 4B is a partial cross-sectional view thereof,further showing the offset protrusions 122. Connecting members withoffset protrusions are particularly useful in embodiments which theconduit openings extending across the length of the panel are offsetfrom openings extending across the width. FIG. 4C is a partialcross-section view of a connecting member 104 c of another embodiment inwhich the protrusions 122 extend from only a first surface 123 of theconnecting member 104 while a second, opposing surface 125 remainssubstantially flat. As will be described greater detail below,connecting members with protrusions extending from only one side or onesurface are particularly useful in embodiments where there is limitedspace for maneuvering the panels such as when repairing or replacing aportion of a wallboard panel.

FIG. 5A is a schematic illustration of a wallboard panel 500 of anotherpreferred embodiment. As shown in FIG. 5A, the wallboard panel 500generally comprises a gypsum core 502, a plurality of substantiallyrigid reinforcements 504 such as conduits extending through the core,and a rigid frame 506 made of a material other than gypsum. Preferably,the rigid frame is positioned along the edges of the panel.Advantageously, the frame 506 provides the wallboard with uniformlydimensioned and planar edges which facilitates formation of flush jointsbetween abutting panels. In one embodiment, the frame 506 is comprisedof gussets made out of a plastic material such as PVC. In certainpreferred embodiments, the wallboard panel does not include paper facingwhich further reduces mold growth. As will be described in greaterdetail below, the conduits 504 which are attached to the frame 506provide a matrix for the supporting the gypsum within the frame 506 sothat the gypsum 502 does not become detached from the frame 506.

A conventional gypsum wallboard is typically manufactured by pre-mixingingredients including calcium sulfate hemi hydrate into an aqueousslurry, which is then deposited between two sheets of facing paper. Asthe slurry is deposited onto a first sheet of facing paper, the othersheet of facing paper is placed on top of the deposited slurry andbonded to the edges of the first facing paper. The slurry is thenallowed to set between the two sheets of the paper to form a gypsumboard. As such, the two sheets of facing paper constrain and limit theflow of the slurry, thereby allowing the slurry to set into board form.Additional descriptions of the formation of a gypsum core board aredisclosed in U.S. Pat. No. 6,902,821, which is hereby incorporated byreference in its entirety.

The wallboard panel of the preferred embodiments such as that shown inFIG. 5 can be manufactured without the facing papers as the frame 506 isconfigured to constrain or limit the slurry flow. In one embodiment, thewallboard panel can be manufactured by first forming a generallyrectangular frame 506 comprising gussets interconnected byreinforcements using methods known in the art, followed by applying aslurry comprising gypsum or other curable material onto the framework,and then allowing the gypsum or other curable material to set and cureinto solid panel form. Since the slurry will be confined within the areadefined by the frame and supported by the reinforcements, facing paperscan be eliminated in the formation of the gypsum wallboard panels inthese embodiments.

Persons of ordinary skill in the art will understand that thecomposition of such other slurry materials will vary for each generaltype of wallboard. In addition, depending on various factors including,among others, material cost and the panel's intended application,variations of the basic core composition may exist within each generalcategory of wallboard type (drywall, plasterboard, cement fiber board,mineral fiber panel, Sheetrock, etc.).

As also shown in FIG. 5A, the reinforcements 504 embedded in the gypsumcore are preferably plastic tubing having a substantially circularcross-section, however it will be appreciated that the number of plastictubing shown is for illustrative purposes only and do not represent theonly embodiment or the preferred embodiment. FIG. 5A also shows that theframe 506 preferably comprises elongated, rectangular plastic piecesthat provide added strength to the wallboard panel 500. In oneembodiment, the frame 506 is also made of a PVC material. In anotherembodiment, the frame 506 is positioned along the outer border of thegypsum core 502 and serves as a sidewall of the panel.

As also shown in FIG. 5A, a series of openings 508 can be formed in theframe 506 and configured to receive end portions 510 of thereinforcements 504. Preferably, the end portions of the reinforcements504 such as the plastic tubing as shown in FIG. 5A are positioned in amanner such that they are flush with the exterior surface 512 of theframe 506. In some preferred embodiments, the openings 508 in the frame506 have a substantially oval shape while the plastic tubing has acircular cross-section. The opening in the frame and the diameter of theplastic tubing are configured such that the openings in the framecompress and slightly flatten the plastic tubing when the end portionsof the tubing are inserted into the opening. In one embodiment, theopening has a width of about ⅞ inch. As will be described in greaterdetail below, the compressed PVC tubing will provide a certain amount offlex when a nail or fastener is inserted through the tubing.

In other implementations as shown in FIG. 5B, the frame 506 can beattached to the edges of a conventional drywall panel 570. Thereinforcements 504 can also extend across a face 572 of the drywallpanel 570 as opposed to being embedded in the gypsum core. FIG. 5Cillustrates a wallboard panel 550 of yet another preferred embodiment.As shown in FIG. 5C, the wallboard panel 550 comprises a gypsum core 552and a substantially rigid reinforcement 554 embedded therein. In oneembodiment, the reinforcement 554 comprises a plastic sheet havingperforated openings 508 formed therein. Preferably, the plasticreinforcement sheet extends to at least one edge 505 of the panel 550 toprovide a bondable surface 556. The perforated openings 508 are formedin the plastic reinforcement sheet 554 to reduce weight and improvebonding with the gypsum core 552.

Reduce Nail Pop

FIG. 6 is a partial schematic illustration of one embodiment of thewallboard panel 102 a that is designed to substantially reduce nailpops. As shown in FIG. 6, a recess 600 is formed in the core material110 adjacent to a conduit 112. A fastener 602 such as a nail is extendedinto the recess 600, through the conduit 112, and into a wall stud 604.When the fastener 602 is inserted through the conduit, an upper portion603 of the conduit wall is slightly pressed downwards toward a lowerportion 605 of the conduit wall. After the fastener 602 is extended intothe conduit 112, the upper portion of the conduit wall 603 flexesslightly upwards, thus stabilizing the fastener and limiting itsmovement. The recess 600 is then patched using a resin or other patchingmaterial 608 known in the art in a manner such that a space 606 is leftbetween the resin 608 and the fastener 602. As such, when there ismovement between the stud and the drywall panel, movement of thefastener would be reduced because it is secured and stabilized by theconduit which is comprised of a material more rigid than the corematerial which is typically gypsum or the like. Moreover, even if thefastener is shifted or moved after installation, the spacing 606 betweenthe fastener and the patching material further reduces the likelihood ofthe fastener showing through the exterior surface 610 of the walls.

Eliminates Need to Align Panel Edge to a Stud

FIG. 7 illustrates the manner in which the wallboard system 100 isinstalled. As shown in FIG. 7, individual wallboard panels 102 a, 102 bare positioned adjacent to each other in a manner such that the jointarea 700 can be located anywhere, such as between studs 702. Since theedges of adjacent panels are configured to be securely attached to eachother such as by welding, there is no need to nail the edges toindividual studs as commonly practiced in the prior art. The panels canbe mounted to the building frame 702 by inserting a nail or any othertype of fastener through any of the plurality of reinforcement conduitsextending through the panel. In some embodiments, indicia 704 arepositioned on the exterior surface 610 of the panel to indicatelocations of the reinforcement conduits. The reinforcement conduits andframe in the wallboard panels provide structural reinforcement to thewallboard panel. The orthogonal arrangement of the conduits provides anetwork of reinforcements, which is particularly useful in reinforcinginterior walls of a building structure.

Facilitate Drywall Repair

FIGS. 8A and 8B show the manner in which the wallboard system 100illustrated in FIGS. 1A and 1B allow for easy repair and replacement ofportions of the wallboard. As shown, to replace a portion 802 of awallboard panel 800, a replacement piece 804 and replacement connectingmembers 806 can be cut out and attached to the panel 800 via solventwelding, heat welding, ultrasonic welding, cementing or other knownprocesses to form a flush joint. As shown, the conduits 112 extendingthroughout the panel 800 in a grid pattern permit for easy alignment ofreplacement piece 804. In practice, a properly sized and configuredreplacement piece 804 is cut out to match the section 802 in thewallboard panel that needs repair. Properly sized connecting members 806are also cut out to attach the replacement piece 804 to the panel.Preferably, connecting members with protrusions 807 extending from onlyone side 809 or surface is used in this embodiment. The protrusions 807are inserted into respective openings formed by the conduits in thereplacement piece and bonded to the conduits thereby leaving a strip ofbonding surface 211 along each edge of the replacement piece 804. Thereplacement piece 804 is then joined to and aligned with the rest of thewallboard panel by securely attaching the bonding surface 211 to theconduits in the connecting members 806 by welding, cementing, or otherknow processes. Since the reinforcement grid extends across the entirepanel, any section of the wallboard panel can be replaced in this mannerwith replacement pieces.

Corner Beads

FIGS. 9A and 9B illustrate a corner bead 900 of one preferred embodimentconfigured to be inserted between the abutting edges of two adjoining,non-overlapping wallboard panels positioned at a relative angle to eachother to form an outside corner. As shown in FIG. 9A, the corner bead900 generally includes an elongated body 902 having at least twointerior surfaces 904 a, 904 b extending along the length of the body902 and disposed at an angle 906 relative to each other. The angle 906is preferably configured to correspond to the angle between the edges ofthe abutting and non-overlapping panels forming the outside corner. Inone embodiment, the angle 906 is preferably 30°, 45°, 90°, or 135°. Thecorner bead 900 is configured to fit between the ends of the abuttedpanels in a manner such that the interior surfaces of the corner beadare in contact with a respective panel edge. In certain preferredimplementations, the width of each interior surface 904 a, 904 b issubstantially the same as the thickness of the wallboard panel,preferably ⅜ inch, ½ inch, ¾ inch, or 1 inch. The length of the cornerbead can also be sized to match the height of the wallboard.Additionally, the corner bead is preferably made of a plastic materialthat is solvent or adhesive bondable to other plastic materials.

As also shown in FIG. 9A, a plurality of protrusions 906 are formedalong each interior surface 904 a, 904 b of the corner bead. Theprotrusions 906 are configured to be inserted into the conduits spacedalong the edges of the wallboard panels as described above. Inalternative embodiments, recesses are formed along each surface 904 a,904 b to receive the ends of the conduits or reinforcements thatprotrude outwardly from the abutting edge of the panels. Preferably, thecorner bead 900 is inserted between and securely attached to theabutting wallboard panels forming the outside corner. In one embodiment,the protrusions 906 on the corner bead 900 are attached to the conduitsand/or reinforcements spaced along the edges of each wallboard panelusing known bonding techniques such as solvent welding, adhesivebonding, cement bonding, ultrasonic welding, or heat welding. In anotherembodiment, the protrusions 906 are attached to each wallboard panel viaan interference fit with the conduits spaced along the panel edge.However, it will be appreciated that there are embodiments in which thecorner bead does not contain the protrusions and that the interiorsurfaces of the corner bead are directly bonded to the side edges of thepanels.

As illustrated in FIG. 9A, the corner bead 900 also has one or moreexterior surfaces 905 which provide a finish to the outside corner ofcertain preferred embodiments. As shown in FIG. 9B, the exterior surface905 can assume a variety of different configurations such as standardorthogonal 908, bull nosed 910, diagonal 912, or ornamental 914.

FIG. 10 illustrates the corner bead 900 being used to finish an outsidecorner formed by two abutting, non-overlapping drywall panels 1002, 1004of one preferred embodiment. The drywall panels 1002, 1004 arepreferably gypsum panels having a plurality of conduits extendingtherethrough and a plastic frame 1003 along its four edges such as thatshown and described in FIGS. 5A and 5B. Since the abutting panels arepositioned in a manner such that the side edge of one panel does notoverlap onto the face of the adjacent panel, the joint area 1008 betweenthe panels needs to be filled in order to finish the outside corner. Asshown in FIG. 10, the outside corner is finished by attaching theinterior surfaces of the corner bead 900 to the edges of the two drywallpanels 1002, 1004. In one embodiment, the protrusions 906 on theinterior surfaces of the corner bead are bonded to conduits spaced alongthe side edges of the frame 1003. The exterior surface 905 of the cornerbead forms the corner between the two panels. Advantageously, the cornerbead 900 can be easily installed and fills the joint area withoutoverlapping onto the face of the panels which helps form a smooth,finished exterior corner surface.

FIG. 11A illustrates a corner bead 1100 of another preferred embodimentconfigured to finish an inside corner of one preferred embodiment. Asshown in FIG. 11A, the corner bead 1100 comprises an elongated body 1102having a first and second surfaces 1112 a, 1112 b positioned at an angle1114 relative to each other. Preferably, the angle 1114 is selected tocorrespond to the angle formed between two abutting wallboard panelsforming the inside corner, such as between the ceiling panel and wallpanel or between adjacent wall panels at an inside corner. In apreferred embodiment, the width of each surface 1112 a, 1112 bcorresponds to the width of the wallboard panel, such as ⅜ inch, ½ inch,¾ inch, or 1 inch. The corner bead 1100 further includes protrusions1106 that extend outwardly from the surfaces 1112 a, 1112 b of theelongated body 1102 as shown in FIG. 11A. The protrusions 1106 areconfigured to be inserted into conduits spaced along the edges of thewallboard panels so as to secure the corner bead to the wallboardpanels. Preferably, the corner bead is made of a plastic material thatcan be bonded to other plastic materials.

FIGS. 11B-11E illustrate the manner in which the corner bead 1100 of oneembodiment can be formed. As shown in FIG. 11B, the corner bead 1100 canbe formed from a plastic strip 1114 that is foldable along alongitudinal axis 1104. The plastic strip 1114 further includespre-formed tabs or protrusions 1106 that can be extended outwardly froma surface 1103 of the strip 1114 in a manner as shown in FIG. 11C. FIG.11D is a cross-section view of the corner bead 1100 showing the tabs1106 extending from the body 1102 of the corner bead 1100. In oneembodiment, the tabs 1106 are configured to be inserted into theconduits extending across the wallboard panels as described above. Asshown in FIG. 11E, the corner bead 1100 is bendable along thelongitudinal axis 1104 to form an angle suitable for placement betweentwo wallboard panels. In one embodiment, this angle can be adjusteddepending on the angle of the inside corner.

FIG. 12 illustrates the manner in which the corner bead 1100 of FIGS.11A-E is used to finish an inside corner formed of two wallboard panels1200, 1202 positioned an angle. As shown in FIG. 12, the surfaces 1112a, 1112 b of the corner bead are in contact with an edge of eachrespective wallboard panel 1200, 1202. In one embodiment, theprotrusions on the corner bead are inserted in and bonded to theconduits spaced along the edges of the panels. In another embodiment,the surfaces are directly bonded to the plastic frame formed along theedges the panel. As shown in FIG. 12, an edge portion 1122 of the cornerbead 1110 which connects the two surfaces fills the joint area betweenthe two panels without overlapping onto the face of the panels.Advantageously, the corner inserts 1000, 1100 for inside and outsidecorners facilitate formation of flush and substantially seamless cornersin the wallboard system of the preferred embodiments. Moreover, thecorner inserts fill the joint areas without overlapping onto the face ofthe panels which result in a much smooth exterior corner surface. Thecorner inserts 1000, 1100 can be easily installed as they are configuredwith protrusions adapted to fit into the openings formed in thesidewalls of the panel as described above, or in other embodiments theycan be directly bonded to plastic frames formed along the panel.

Wallboard Frame

In certain preferred embodiments, the wallboard panel can be made byretrofitting a pre-formed gypsum drywall panel with a frame so that theframed drywall panel can be installed in the manner as described aboveand also have the advantageous features as described above. FIG. 13A isa schematic illustration of a wallboard frame 1300 of one preferredembodiment configured to retrofit a conventional drywall panel so thatthe panel would have with a uniform, planar sidewall and/or weldableedges. As shown in FIG. 13A, the frame 1300 includes a plurality ofelongated sidewalls 1302 a-d joined together to define a generallyrectangular space 1304. In one embodiment, the rectangular space 1304 isapproximately 4 feet by 8 feet and configured to receive a pre-formeddrywall panel. However, it will be appreciated that the frame 1300 canassume a variety of different dimensions and shapes. In a preferredembodiment, the frame 1300 is made of a plastic material in which eachsidewall 1302 a-d comprises a rigid plastic material such as PVC. Incertain preferred implementations, the sidewalls are dimensioned andshaped substantially similarly as the gussets described above. As alsoshown in FIG. 13A, the frame 1300 further includes a backing portion1306 preferably in the form of a plurality of reinforcements extendingbetween opposing sidewalls. In one embodiment, the backing portion 1306comprises a plurality of conduits spaced apart in a grid pattern asdescribed above. The backing portion 1306 provides a mounting supportfor the drywall panel that will be mounted in the space 1304 defined bythe frame 1300.

In a preferred embodiment, a lower exterior surface 1308 of thereinforcements 1306 is substantially flush with a lower exterior surface1310 of the sidewalls 1302 a-d of the frame 1300. This allows the frameto be nailed to a stud through the reinforcements 1306 without bendingthe frame. In another preferred embodiment, the reinforcements 1306 arepositioned such that the distance between an upper exterior surface 1312of the reinforcements 1306 and a plane defined by an upper exteriorsurface 1314 of the sidewalls 1302 a-d is substantially the same as thethickness of the drywall panel. As such, the drywall panel will fitflushly in the frame with the exterior facing of the mounted drywallpanel substantially flush with the frame.

As also shown in FIG. 13A, openings 1316 are preferably formed along thesidewalls 1302 a-d of the frame 1300 to receive end portions 1318 of thereinforcements 1306. In the embodiment as shown in FIG. 13A, thereinforcements comprise a plurality of conduits. As described in otherembodiments above, the conduits and openings provide an alignment andattachment system between adjacent drywall panels. In some embodiments,the frame 1300 can be provided in a disassembled kit form. The kitpreferably includes disassembled sidewalls having adjustment slotsthereon that would allow quick assembly of the frame into variousdifferent dimensions. For example, if a frame of non-standard dimensionsis required, the disassembled sidewalls can be cut to the desired lengthon the job site and the adjustment slots spaced along the sidewalls canfacilitate quick assembly of the sidewalls to form the frame.

A pre-formed drywall panel 1320 can be mounted in the frame 1300 in themanner as shown in FIG. 13B. Preferably, the panel 1320 is positionedsuch that a face 1322 of the panel 1320 is attached to and supported bythe backing portion 1306. Preferably, the face of the panel 1322 isadhered to the reinforcements by adhesive. As shown in FIG. 13B, whenthe panel 1320 is mounted, an exterior face 1324B is preferably flushwith the upper surface 1314 of the frame 1300 thereby providing thewallboard panel a uniform, planar exterior surface. In some embodiments,the panel 1320 can be attached to the upper exterior surface 1314 of theframe sidewalls 1302 a-d. In other embodiments, the frame 1300 can befirst mounted to a wall stud or building support structure beforeattaching the drywall panel 1320 to the frame.

Although the above-disclosed embodiments have shown, described, andpointed out the fundamental novel features of the invention as appliedto the above-disclosed embodiments, it should be understood that variousomissions, substitutions, and changes in the form of the detail of thedevices, systems, and/or methods shown may be made by those skilled inthe art without departing from the scope of the invention. Furthermore,it will be appreciated that the dimensions of certain features shown inthe figures may be exaggerated for illustrative purposes.

1. A wallboard system, comprising: a plurality of panels, each of saidpanels having a plurality of conduits extending through the panelbetween a first edge and a second edge; and a connector comprising aplurality of protrusions sized to fit within the respective conduits. 2.The wallboard system of claim 1, wherein the conduits extend betweenopposite edges of each panel.
 3. The wallboard system of claim 1,further comprising a second plurality of conduits, wherein the secondplurality of conduits are orthogonal to the first plurality of conduits.4. The wallboard system of claim 1, wherein the connector comprises anelongated strip from which the protrusions project.
 5. The wallboardsystem of claim 4, wherein the protrusions project from opposingsurfaces of the strip.
 6. The wallboard system of claim 1, wherein theconduits are made of a plastic material selected from the groupconsisting of PVC, polycarbonate, polystyrene, ABS, nylon, PET,acrylics, or combinations thereof.
 7. The wallboard system of claim 1,wherein the protrusions on the connector and the conduits are weldedtogether.
 8. The wallboard system of claim 1, wherein the connector hasat least two surfaces that are disposed at an angle relative to eachother, wherein said protrusions project from the two surfaces.
 9. Thewallboard system of claim 1, wherein the panel is drywall.
 10. Thewallboard system of claim 1, wherein the panel is plasterboard.
 11. Thewallboard system of claim 1, wherein the panel is cement fiberboard. 12.The wallboard system of claim 1, wherein the panel is mineral fiber. 13.A drywall panel having a plurality of elongated reinforcements extendingthrough from one edge to another.
 14. The drywall panel of claim 13,further comprising indicia on the exterior of the panel indicatingposition of the reinforcements.
 15. The drywall panel of claim 13,wherein said elongated reinforcements comprise a network of horizontaland perpendicular reinforcements.
 16. The drywall panel of claim 13,wherein an end portion of each reinforcement protrudes outwardly from anedge of the panel.
 17. The drywall panel of claim 16, further comprisinga gusset disposed along the edge of the panel, said gusset having aplurality of openings configured to receive the end portion of thereinforcement.
 18. A plurality of panels comprised of gypsum, each ofthe panels having two opposing faces and an edge portion comprised of amaterial other than gypsum, said material having a bonding propertywhich allows an edge portion of one panel to be attached to an edgeportion of another panel by bonding so as to securely fasten the edgeportions together.
 19. The panels of claim 18, wherein the bondingproperty comprises a property which allows the material to be weldableto other materials.
 20. The panels of claim 18, wherein the edge portionmaterial is plastic.
 21. The panels of claim 18, wherein said edgeportion comprises a planar surface that is perpendicular to the opposingfaces of the panel.
 22. The panels of claim 18, wherein the edge portionof one panel is attached to the edge portion of another panel by bondingboth edge portions to a connector that is disposed therebetween.
 23. Awallboard panel comprised of gypsum, said panel having an edge portioncomprised of a plastic material.
 24. The wallboard panel of claim 23,wherein the edge portion comprises opposing edges of the panel, saidopposing edges are interconnected by reinforcements extending across thegypsum.
 25. The wallboard panel of claim 24, wherein the edge portioncomprises a frame that borders the edges of the panel.
 26. The wallboardpanel of claim 23, wherein said plastic material is attached to a faceof the wallboard panel.
 27. A corner bead for finishing a corner ofabutted, non-overlapping drywall panels, said corner bead configured tofit wholly between ends of the abutted panels without overlapping ontofaces of the panels.
 28. The corner bead of claim 27, further comprisingtwo elongated surfaces disposed at an angle relative to each other,wherein each surface is configured to contact an end of a respectiveabutting panel.
 29. The corner bead of claim 27, further comprising aplurality of protrusions extending from each of said elongated surfaces.30. The corner bead of claim 27, wherein said corner bead is configuredto attach to the panels without taping or nailing.
 31. The corner beadof claim 27, wherein said corner bead is configured for finishing aninside corner.
 32. The corner bead of claim 27, wherein said corner isconfigured for finishing an outside corner.
 33. The corner bead of claim28, wherein the angle between the elongated surfaces of the corner beadis adjustable.
 34. A wallboard system comprising: a pair of panelscomprised of gypsum core, each of the panels having an edge portioncomprised of material other than gypsum; and a corner bead between edgesof adjacent panels, said corner bead having a pair of surfaces disposedat an angle relative to each other, said corner bead comprised of amaterial, wherein the edge portion material and the corner bead materialhave bonding properties which allow respective edge portions of thepanels to be attached to respective surfaces of the corner bead bybonding.
 35. A method of installing a plurality of wallboard panels,comprising: positioning a first drywall panel having an edge portioncomprised of a material other than drywall to a second drywall panelhaving an edge portion comprised of a material other than drywall; andattaching the edge portion of the first drywall panel to the edgeportion of the second drywall panel by a method selected from the groupconsisting of cement bonding, adhesive bonding, solvent welding, heatwelding, ultrasonic welding, and combinations thereof.
 36. The method ofclaim 35, wherein the step of attaching the edge portions of the drywallpanels comprises placing a connector adjacent a respective edge portionof each drywall panel and adhering said connector to said respectiveedge portions.
 37. The method of claim 36, wherein placing a connectoradjacent a respective edge portion comprises placing a connector havingspaced protrusions extending therefrom adjacent an edge of the firstdrywall panel, inserting a plurality of the protrusions into the edgeportion of the first panel, and inserting another plurality of theprotrusions into the edge portion of the second drywall panel, andadhering the inserted plurality of protrusions to the drywall material.38. The method of claim 37, further comprising inserting a fastener intoa face of the drywall panel, through one of a plurality of conduitsembedded in the drywall, and into a support frame.
 39. A method ofrepairing a drywall panel, comprising: cutting an opening in a drywallpanel having a plurality of conduits extending therethrough; preparing adrywall insert sized to fit within the opening such that a plurality ofconduits through the insert is parallel to the plurality of conduits inthe panel; and inserting at least one connector into at least some ofthe conduits so as to fasten the insert into the panel.
 40. The methodof claim 39, further comprising orienting the inserts so that a secondplurality of conduits of the insert orthogonal to the first plurality ofthe insert is parallel to a second plurality of conduits of the panelorthogonal to the plurality of conduits to the panel.
 41. A frame formounting gypsum drywall, comprising: a perimeter edge portion configuredto retain a panel of said gypsum drywall with plural edges of the paneladjacent respective plural edges of said perimeter edge portion; and abacking portion attached to said edge portion and disposed within aspace defined by the perimeter of the edge portion.
 42. The frame ofclaim 41, wherein said edge portion comprises a plurality of elongatedsections defining a substantially rectangular area.
 43. The frame ofclaim 42, wherein at least one elongated section is made of a plasticmaterial.
 44. The frame of claim 42, wherein at least two of theelongated sections are disposed orthogonally to each other therebyforming a corner.
 45. The frame of claim 42, wherein plural openings areformed in at least one elongated section.
 46. The frame of claim 41,wherein said edge portion is approximately 4 feet wide and 8 feet long.47. The frame of claim 41, wherein the backing portion extends cross thespace defined by the perimeter of the edge portion.
 48. The frame ofclaim 41, wherein the backing portion comprises a plurality of conduits.49. A method of applying a frame to a gypsum drywall panel, comprising:providing a substantially rigid frame having a backing material disposedwithin a space defined by said frame; and attaching said gypsum drywallpanel to said frame.
 50. The method of claim 49, wherein providing saidframe comprises joining a plurality of elongated legs together in amanner such that at least two of the legs are disposed orthogonally toeach other.
 51. The method of claim 50, wherein attaching said gypsumdrywall panel to said frame comprises attaching a face of said gypsumdrywall panel to said elongated legs.
 52. The method of claim 49,wherein forming said frame comprises attaching a backing material to atleast one edge of the frame.
 53. The method of claim 52, wherein saidbacking material comprises a conduit.
 54. The method of claim 52,wherein attaching said gypsum drywall panel comprises attaching a faceof the panel to said backing material.